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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Quantification of Aerosol Transmission through Stress Corrosion Crack-Like Geometries

The formation of a stress corrosion crack (SCC) in the canister wall of a dry cask storage system (DCSS) has been identified as a potential issue for the long-term storage of spent nuclear fuel. The presence of an SCC in a storage system could represent a through-wall flow path from the canister interior to the environment. Modern, vertical DCSSs are of particular interest due to the commercial practice of using more significant backfill pressures in the canister, up to approximately 800 kPa. This pressure differential offers a relatively high driving potential for blowdown of any particulates that might be present in the canister. In this study, the rates of gas flow and aerosol transmission of a spent fuel surrogate through an engineered microchannel with dimensions representative of an SCC were evaluated experimentally using coupled mass flow and aerosol analyzers. The microchannel was formed by mating two gage blocks with a linearly tapering slot orifice nominally 13 μm (0.005 in.) tall on the upstream side and 25 μm (0.0010 in.) tall on the downstream side. The orifice is 12.7 mm (0.500 in.) wide by 8.86 mm (0.349 in.) long (flow length). Surrogate aerosols of cerium oxide, CeO 2 , were seeded and mixed with either helium or air inside a pressurized tank. The aerosol characteristics were measured immediately upstream and downstream of the simulated SCC at elevated and ambient pressures, respectively. These data sets are intended to add to previous testing that characterized SCCs under well-controlled boundary conditions through the inclusion of testing improvements that establish initial conditions in a more consistent way. These ongoing testing efforts are focused on understanding the evolution in both size and quantity of a hypothetical release of aerosolized spent fuel particles from failed fuel to the canister interior and ultimately through an SCC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

In Situ X-ray Microtomography of Stress Corrosion Cracking and Corrosion Fatigue in Aluminum Alloys

Structural materials are subjected to combinations of stress and corrosive environments that work synergistically to cause premature failure. Therefore, studies on the combined effect of stress and corrosive environments on material behavior are required. Existing studies have been performed in two dimensions that are inadequate for full comprehension of the three-dimensional (3D) processes related to stress corrosion cracking (SCC) and corrosion-fatigue (CF) behavior. Recently, x-ray synchrotron tomography has evolved as an excellent technique to obtain the microstructure in 3D. Moreover, being nondestructive in nature, x-ray synchrotron tomography is well suited to study the evolution of microstructure with time (4D, or fourth dimension in time). Furthermore, this article presents our recent 4D studies on SCC and CF of Al 7075 alloys using x-ray synchrotron tomography.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Chloride-Induced Stress Corrosion Cracking Characteristics of the Used Nuclear Fuel Canister Material

The used nuclear fuel (UNF) dry storage systems are located in the coastal and lake/river-side regions, the service time of which is 60 years and more. One type of dry storage systems is composite of a thin-walled austenitic stainless steel (SS) welded canister and a concrete overpack. The air flows through the canister surface and brings away the decay heat. Meanwhile, the air brings the salt species into the canister and make them deposit on the surface. The salt deposit will be deliquescent when absorbing the moisture air, being corrosive to the surface. NRC and other programs claimed that chloride induced stress corrosion cracking (CISCC) would lead to the canister failure, being one of the major technical gaps for extended dry storage systems. CISCC is induced by the combined influence of the aggressive environment (chloride ions in our case) and tensile stresses (residual stresses in our case) on the susceptible materials (the austenitic SS in our case). Chrome (Cr), as one of the chemical compositions of SSs, plays an important role in the corrosion resistance. It can form a chrome-rich inner barrier oxide layer to prevent the SS from corrosion. However, chloride ions can easily break down the barrier and accelerate dissolution of the underlying metal, the phenomena of which is pitting corrosion. Pitting is the precursor to CISCC as which provides the combination of a local aggressive solution chemistry and a stress concentrating feature. Accordingly, CISCC invariably originates from the pits, and cracks that have nucleated on pit walls can grow around the pit and coalesce to form a complete through-crack. Significant tensile residual stresses, caused by the welding process, exist throughout the thickness of the canister wall. Enos and Bryan found that large residual stresses were in the full-scale mockup container simulating a canister, which supports the SCC propagation. It is therefore interesting to achieve a good knowledge about the effect of welding on the durability of SSs, especially in the corrosive environment. In order to understand the fundamental of the cracking behaviors, it's vital to elucidate the microstructure and microchemistry of cracking. This study focused on observing the CISCC characteristics of the UNF canister material exposed to the humid environment with salt deposit. Extensive micro-characteristics have been achieved by the techniques include focused ion beam/ scanning electron microscope (FIB/SEM), transmission electron microscopy (TEM), energy dispersive spectroscopy (EDS), and optical profiler. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Irradiation Assisted Stress Corrosion Cracking of Austenitic Stainless Steel in BWR Conditions

As a first step toward full scale utilization of the Advanced Test Reactor (ATR) and associated post irradiation examination (PIE) equipment at INL, the NRC and INL staffs have formulated a test program that is designed to help to establish INL and the Nuclear Science User Facilities (NSUF) as a viable destination for irradiation and PIE of reactor structural materials. This initial research program utilized two materials (304 Stainless Steel weld Heat Affected Zone (HAZ) and sensitized 304L stainless steel) that have previously been irradiated at the Halden reactor in Norway and tested at Argonne National Laboratory (ANL) so that test results may be compared, thereby establishing a measure of comparability between Halden and ATR irradiations. A secondary objective of this test program was to characterize the quality of data produced using INL’s newly constructed irradiation assisted stress corrosion cracking (IASCC) test cells. The specimens were be tested in typical boiling water reactor (BWR) conditions to measure stress corrosion cracking (SCC) and fracture toughness of un-irradiated specimens and then IASCC and fracture toughness of specimens irradiated to a fluence equal to approximately 1.0 X 10 21 n/cm 2 (E > 1 MeV).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Measuring the residual stress and stress-corrosion cracking susceptibility of additively manufactured 316L by ASTM G36-94

Residual stress is a contributor to stress-corrosion cracking (SCC) and a common byproduct of additive manufacturing (AM). In this work, the relationship between residual stress and SCC susceptibility in laser powder bed fusion AM 316L stainless steel was studied through immersion in saturated boiling magnesium chloride per ASTM G36-94. The residual stress was varied by changing the sample height for the as-built condition and additionally by heat treatments at 600, 800, and 1200 °C to control, and in some cases reduce, residual stress. In general, all samples in the as-built condition showed susceptibility to SCC with the thinner, lower residual stress samples showing shallower cracks and crack propagation occurring perpendicular to melt tracks due to local residual stress fields. The heat-treated samples showed a reduction in residual stress for the 800 and 1200 °C samples. Both were free of cracks after >300 hours of immersion in MgCl 2 , while the 600 °C sample showed similar cracking to their as-built counterpart. Geometrically necessary dislocation (GND) density analysis indicates that the dislocation density may play a major role in the SCC susceptibility.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Overaging on Fatigue Crack Propagation and Stress Corrosion Cracking Behaviors of an Al-Zn-Mg-Cu Alloy Thick Plate

The fatigue property as well as stress corrosion cracking (SCC) resistance of an Al-Zn-Mg-Cu alloy thick plate in peak-aged and overaged tempers (T7351 and T7651) is systematically investigated by fatigue crack propagation (FCP) test and slow strain rate test (SSRT). Microstructural characterization is examined by transmission electron microscopy and scanning electron microscopy. Results reveal that the T7351 alloy has lower strength but higher electrical conductivity as compared to T7651 alloy. The FCP resistance of T7351 alloy is superior to that of the T7651 alloy due to the coarser precipitates in the highly overaged alloy in which the strain localization is reduced by promoting homogeneous slip. In addition, the SSRT test suggests a higher SCC resistance in T7351 alloy. The enhanced SCC resistance is found to depend on grain boundary precipitate characteristics and crack propagation resistance of the alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Testing of Microchannels and Lab-Grown Stress Corrosion Cracks for Quantification of Aerosol Transmission

The formation of a stress corrosion crack (SCC) in the canister wall of a dry cask storage system (DCSS) has been identified as a potential issue for the long-term storage of spent nuclear fuel. The presence of an SCC in a storage system could represent a through-wall flow path from the canister interior to the environment. Modern, vertical DCSSs are of particular interest due to the commercial practice of using higher backfill pressures in the canister, up to approximately 800 kPa, compared to their horizontal counterparts. This pressure differential offers a relatively high driving potential for blowdown of any particulates that might be present in the canister. In this study, the rates of gas flow and aerosol transmission of a spent fuel surrogate through an engineered microchannel with dimensions representative of an SCC were evaluated experimentally using coupled mass flow and aerosol analyzers. The microchannel was formed by mating two gage blocks with a linearly tapering slot orifice nominally 13 μm (0.005 in.) tall on the upstream side and 25 μm (0.0010 in.) tall on the downstream side. The orifice is 12.7 mm (0.500 in.) wide by 8.86 mm (0.349 in.) long (flow length). Surrogate aerosols of cerium oxide, CeO 2 , were seeded and mixed with either helium or air inside a pressurized tank. The aerosol characteristics were measured immediately upstream and downstream of the simulated SCC at elevated and ambient pressures, respectively. These data sets are intended to add to previous testing that characterized SCCs under well-controlled boundary conditions through the inclusion of testing improvements that establish initial conditions in a more consistent way. While the engineered microchannel has dimensions similar to actual SCCs, it does not reproduce the tortuous path the aerosol laden flow would have to traverse for eventual transmission. SCCs can be rapidly grown in a laboratory setting given the right conditions, and initial characterization and clean-flow testing has begun on lab grown crack samples provided to Sandia National Laboratories (SNL). Many such samples are required to produce statistically relevant transmission results, and SNL is developing a procedure to produce samples in welded steel plates. These ongoing testing efforts are focused on understanding the evolution in both size and quantity of a hypothetical release of aerosolized spent fuel particles from failed fuel to the canister interior and ultimately through an SCC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

A Phenomenological Model for the Transport and Plugging of Aerosol through Stress Corrosion Cracks

Recent experimental evidence from Sandia (2018) demonstrated partial microchannel plugging due to particulate deposition. A direct consequence is that the accuracy of consequence assessments can be improved by accounting for the leak path deposition of aerosol in the source term. The filtration effect of microchannels, such as cracks, is relevant to the source term assessments. An important side effect of aerosol deposition in leak paths could be the plugging of the leak path. This report summarizes current progress (as of end of FY19) on the development of a phenomenological model of aerosol transport, deposition, and plugging through microchannels. The purpose is to introduce a generic, reliable numerical model for prediction of aerosol transport, deposition, and plugging in leak paths that are similar to stress corrosion cracks while accounting for potential plugging formation. This effort includes (i) development of a numerical model to analyze the various deposition processes in leak paths and provide quantitative estimates of penetration factors, as well as an understanding of the variables that affect them, (ii) confirmation of model validity with theoretical and experimental data, and (iii) parametric analysis for different scenarios including various particle sizes, pressures, and crack dimensions. Such a model could be used to improve the accuracy of consequence assessments and reduce the uncertainty of radiological consequence predictive analyses by taking the filtering effect of leak path aerosol deposition and plugging into account in the source term. This report includes: (i) an overview of main stress corrosion cracking characteristics, (ii) an overview of the developed numerical model to analyze the various deposition processes in leak paths, to provide quantitative estimates of penetration factors, and to gain an understanding of the variables that affect them, (iii) a summary of validation results and verification of the model’s validity with recent experimental results from Sandia and others, and (iv) a model application example.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Development of a numerical model for simulating stress corrosion cracking in spent nuclear fuel canisters

Abstract Prediction and detection of the chloride-induced stress corrosion cracking (CISCC) in Type 304 stainless steel spent nuclear fuel canisters are vital for the lifetime extension of dry storage canisters. This paper conducts a critical review that focuses on the numerical modeling and simulation on the research progress of the CISCC. The numerical models emphasizing the residual stress, susceptible microstructure, and corrosive environment are summarized individually. Meanwhile, the simulation studies on the role of hydrogen-assisted cracking are reviewed. Finally, a multi-physical numerical model, which combines the different fields is proposed based on our recent investigation.

Materials Science↗
DOE OSTI2015

STRESS CORROSION CRACK GROWTH RESPONSE FOR ALLOY 152/52 DISSIMILAR METAL WELDS IN PWR PRIMARY WATER

As part of ongoing research into primary water stress corrosion cracking (PWSCC) susceptibility of alloy 690 and its welds, SCC tests have been conducted on alloy 152/52 dissimilar metal (DM) welds with cracks positioned with the goal to assess weld dilution and fusion line effects on SCC susceptibility. No increased crack growth rate was found when evaluating a 20% Cr dilution zone in alloy 152M joined to carbon steel (CS) that had not undergone a post-weld heat treatment (PWHT). However, high SCC crack growth rates were observed when the crack reached the fusion line of that material where it propagated both on the fusion line and in the heat affected zone (HAZ) of the carbon steel. Crack surface and crack profile examinations of the specimen revealed that cracking in the weld region was transgranular (TG) with weld grain boundaries not aligned with the geometric crack growth plane of the specimen. The application of a typical pressure vessel PWHT on a second set of alloy 152/52 – carbon steel DM weld specimens was found to eliminate the high SCC susceptibility in the fusion line and carbon steel HAZ regions. PWSCC tests were also performed on alloy 152-304SS DM weld specimens. Constant K crack growth rates did not exceed 5x10-9 mm/s in this material with post-test examinations revealing cracking primarily on the fusion line and slightly into the 304SS HAZ.

alloy 152↗
DOE OSTI2016

Stress Corrosion cracking Testing in Supercritical Carbon Dioxide

This document presents a summary of the ldrd project. The project consists in developing testing capability to address stress corrosion cracking issues in supercritical carbon dioxide. In addition, this project is generating corrosion data. This work aims to help select structural materials for supercritical carbon dioxide energy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2022

FY2022 Status Update: A Probabilistic Model for Stress Corrosion Cracking of SNF Dry Storage Canisters

Understanding the potential risk of stress corrosion cracking of spent nuclear fuel dry storage canisters has been identified as a knowledge gap for determining the safety of long-term interim storage of spent nuclear fuel. To address this, the DOE is funding a multi-lab DOE effort to understand the timing, occurrence, and consequences of potential canister SCC. Sandia National Laboratories has developed a probabilistic model for canister penetration by SCC. This model has been continuously updated at SNL since 2014. Model uncertainties are treated using a nested loop structure, where the outer loop accounts for uncertainties due to lack of data and the inner aleatoric loop accounts for uncertainties due to variation in nature. By separating uncertainties into these categories, it is possible to focus future work on reducing the most influential epistemic uncertainties. Several experimental studies have already been performed to improve the modeling approach through expanded process understanding and improved model parameterization. The resulting code is physics-based and intended to inform future work by identifying (1) important modeling assumptions, (2) experimental data needs, and (3) necessary model developments. In this document, several of the sub-models in the probabilistic SCC model have been exercised, and the intermediate results, as the model progresses from one sub-model to the next, are presented. Evaluating the sub-models in this manner provides a better understanding of sub-model outputs and has identified several unintended consequences of model assumptions or parameterizations, requiring updates to the modeling approach. The following updates have been made, and future updates have been identified.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Systems and methods for application of stress corrosion cracking resistant cold spray coatings

Systems and methods for application of stress corrosion cracking resistant cold spray coatings include a method of forming a partial coating on a canister having a perimeter wall with a surface. The method may include identifying a compromised region on the surface of the wall of the canister, and impacting a substantially linear flow of particles of a powder against an area in the compromised region of the surface in a manner effective to cause the particles of the powder to bond to the surface of the wall to produce a coating on the area of the compromised region. The method may also include moving the substantially linear flow in a direction substantially parallel to the surface of the wall to cause the particles to impact an additional area of the compromised region to cause the particles to bond to the surface of the additional area.

Johnson, Kyle William↗
DOE OSTI2019

Effect of AC Current Density on the Stress Corrosion Cracking Behavior and Mechanism of E690 High-Strength Steel in Simulated Seawater

In this work, we studied the impact of alternating current (AC) density on the stress corrosion cracking (SCC) behavior and mechanism of E690 high-strength steel in simulated seawater with electrochemical measurements, U-bend immersion tests and slow strain rate tensile tests. Results demonstrate that AC enhances both anodic and cathodic processes, especially localized anodic dissolution and hydrogen evolution, which manifests as the increase in i{sub corr} with AC current density rising. Therefore, AC leads to higher SCC susceptibility. Accordingly, SCC is dominated by anodic dissolution (AD) at low AC current density while in a mixed control of AD and hydrogen embrittlement (HE) at high AC current density as a result of increasing hydrogen concentration. Besides, 50 A/m{sup 2} corresponds to the threshold hydrogen concentration of the “hydrogen-induced plasticity to HE” transformation, which is due to the different interactions of dislocation and hydrogen.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Laser glazing of cold sprayed coatings for the mitigation of stress corrosion cracking in light water reactor (LWR) applications

The effect of laser power, traverse speed, and cold spray coating thickness were examined with the goal of mitigating and repairing stress corrosion cracking (SCC) in light water reactor (LWR) environment. For this purpose, SCC-susceptible Alloy 600 substrate material was coated with SCC-resistant Alloy 690 via the cold spray technique. The cold spray coated substrate was then laser-glazed using various laser parameters. Single pass and multiple pass laser glazed regions were created to determine the effects. For this purpose, the area of the fusion zone, depth of the fusion zone, and elemental composition of the cross section were examined by optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy. Additionally, it was shown that chromium dilution from the laser glazed region into the substrate is not a significant factor in laser glazed cold spray coated samples. Separate laser glazed samples were subjected to ASTM 633C to determine coating adhesion. Finally, by using interrupted SCC crack growth rate tests, it was shown that low traverse speeds and high laser powers produce deep fusion zones within the cold sprayed coating and substrate that can be used to seal pre-existing cracks, thus stopping SCC growth.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Understanding the Risk of Chloride Induced Stress Corrosion Cracking of Interim Storage Containers for the Dry Storage of Spent Nuclear Fuel: Evolution of Brine Chemistry on the Container Surface.

Although the susceptibility of austenitic stainless steels to chloride-induced stress corrosion cracking is well known, uncertainties exist in terms of the environmental conditions that exist on the surface of the storage containers. While a diversity of salts is present in atmospheric aerosols, many of these are not stable when placed onto a heated surface. Given that the surface temperature of any container storing spent nuclear fuel will be well above ambient, it is likely that salts deposited on its surface may decompose or degas. To characterize this effect, relevant single and multi-salt mixtures are being evaluated as a function of temperature and relative humidity to establish the rates of degassing, as well as the likely final salt and brine chemistries that will remain on the canister surface.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Historical Review of Stress Corrosion Cracking in Concentrated Uranium-Molybdenum Alloys

This report presents a historical overview of stress corrosion cracking (SCC) in uranium-molybdenum alloys, focusing primarily on bare U-10 wt. pct. Mo (U-10Mo). The fuel system being pursued by the United States High Performance Research Reactor (USHPRR) project incorporates a zirconium interlayer applied early in the process which likely serves as a protective coating. This alloy has been chosen as the high density uranium monolithic fuel for converting research reactors from high enriched uranium (HEU) to low enriched uranium (LEU) fuel for its combination of fuel density and gamma phase stability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Intergranular Stress Corrosion Crack Initiation and Temperature Dependence of Alloy 600 in Pressurized Water Reactor Primary Water

Stress corrosion crack (SCC) initiation of a solution annealed, cold-worked (CW) UNS N06600 (Alloy 600) material was investigated in 360 and 325ºC simulated PWR primary water using constant load tensile instrumented for in-situ detection by the direct current potential drop technique. This CW material with high boron and low carbon bulk concentrations was found to be highly susceptible to SCC. Consistent SCC initiation times were obtained at both temperatures and the thermal activation energy for SCC initiation is estimated at ~116 kJ/mol.

Zhai, Ziqing↗